Abstract: A flat cable includes first and second insulator sheets, and a plurality of conductor elements arranged in parallel relation to one another over the length of the sheets. The first insulator sheet is provided with an adhesive layer. The conductor elements are interposed between the adhesive layer and the second insulator sheet. The first and second insulator sheets are first press-adhered under heat through the adhesive layer, and then bonded by an ultrasonic welding unit. The ultrasonic welding unit includes a horn for imparting ultrasonic oscillations, and an anvil placed in opposition to the horn. The first and second insulator sheets are bonded in the zones which extend along the length of the sheets and are located outside the loci where the conductor elements are arranged. The bonding is performed either continuously or in an intermittent manner. In a flat cable thus produced, the conductor elements embedded therein are efficiently prevented from mutual short-circuiting.

Abstract: A method of fabricating a fiber matrix composite structure including assembling a plurality of plies of fiber-reinforced polymer-matrix material on a mandrel; engaging an ultrasonic horn with the top surface of uppermost ply; and orienting the horn at an acute angle with respect to the top surface and energizing the horn to inducing a shear force in the plies to heat and consolidate the plies.

Abstract: The present invention is direct to angular border on three dimensional sheet material and method of producing. This invention is producing an attractive and finely finished article.

Abstract: A method of achieving a workpiece material property change using a horn with a set of activation teeth as a source of ultrasonic energy and an anvil with a second set of activation teeth. The workpiece is engaged in tension between the two sets of activation teeth.

Abstract: The invention relates to an ultrasonic welding apparatus (100) for welding together at least two superposed sheets (1, 2) made of plastics material and traveling continuously along a predetermined path (F), the apparatus (100) being of the type comprising a sonotrode (101) and an anvil (102) disposed facing each other so that their facing surfaces (101′, 102′) define a through gap (102) through which two superposed sheets (1, 2) to be welded together pass, the gap having an inlet section (104) and an outlet section (105), the sonotrode (101) vibrating at high frequencies to emit ultrasound waves. According to the invention, the anvil is fixed and said facing surfaces of the sonotrode and of the anvil are generally plane and converge towards each other such that the section of said through gap decreases continuously between its inlet section and its outlet section.

Abstract: A method and device for accommodating, by self adjustment, for part interface variations. A self adjusting fixture for accommodating for part interface variation includes a part support member having a first self adjusting member engagement element. The self adjusting fixture also includes a pedestal having a second self adjusting member engagement element engaged with the first self adjusting member engagement element to permit axial deflection of the part support member relative to the pedestal.

Abstract: An apparatus for welding monofilaments at a loom makes possible a method for a continuous process for weaving monofilaments into fabric. The apparatus comprises a stand (15) on which is mounted welding apparatus (16) and a filament alignment block (20). In the method, a monofilament (30a) in the loom is welded to the leading end of a monofilament (30) on a new spool of monofilament. By welding new monofilament to monofilament in the loom, restringing of the loom is avoided.

Abstract: An ultrasonic processing method and apparatus (20) can include a rotatable, ultrasonic horn member (28) that is operatively joined to an isolation member (42) which has high rigidity. A rotatable anvil member (86) can be cooperatively positioned to provide a selected horn-anvil gap (106), and an automated drive (130) can be connected to an actuator (110), or other transfer device, to automatically adjust the horn-anvil gap (106). An electronic processor (128) can be configured to monitor an intermittent gap force detected from an output provided by a force sensor (126), and can provide a drive signal to the automated drive (130) to thereby adjust the horn-anvil gap (106) to operatively maintain a target, gap force value.

Abstract: The apparatus is adapted to weld ultrasonically two or more layers of fabric. The fabrics may be a woven or non-woven fabric of nylon, polyethylene or other polymeric material. The apparatus includes first and second opposed ultrasonically vibratable horns so spaced from one another that the layers of fabric may be passed between them. At least one, and optionally both, of the first and second horns is vibratable in an axial mode.

Abstract: With the ultrasonic adhering method and apparatus, ultrasonic adhesion can be made appropriately, regardless of external environments and a simple structure. The apparatus includes an ultrasonic oscillator for generating ultrasonic vibration, a horn provided in this ultrasonic oscillator for oscillating ultrasonically, and a temperature sensor for sensing the temperature of the horn. A controlling unit is provided for detecting the temperature of the horn and controlling oscillation time of the ultrasonic oscillator in a state of the horn being contact with an object to be adhered in such a manner that the oscillation time has a negative correlation with respect to the temperature of the horn.

Abstract: Apparatus and methods for effecting ultrasonic bonds in sequentially advancing workpiece segments, in a nip defined by a rotary ultrasonic horn and rotary anvil roll. The ultrasonic bonding apparatus comprises support structure comprising anvil support apparatus and horn support apparatus. A closed loop control apparatus is connected to one or both of the anvil support apparatus and horn support apparatus. The closed loop control apparatus comprises a programmable logic controller, a load cell, and an adjustor. Information output from the load cell triggers the closed loop control apparatus through the programmable logic computer and the adjustor to move one or both of the anvil support apparatus and horn support apparatus toward or away from the other in dynamic response to the information output from the load cell, thereby regulating pressure in the nip with ongoing real-time adjustments to distance between the anvil support apparatus and the horn support apparatus.

Abstract: This invention pertains to apparatus and methods for creating ultrasonic bonds in sequentially advancing absorbent article workpiece segments, in a bonding nip. The ultrasonic bonding apparatus comprises a frame, anvil support apparatus, horn support apparatus, closure apparatus, a load cell support member, and a load cell. The ultrasonic horn and the anvil roll collectively are mounted and configured such that the ultrasonic horn and the anvil roll can be brought together, via the closure apparatus, to define the nip therebetween. The load cell is mounted to the load cell support member such that force representative of force exerted on the anvil roll at the nip is detected by the load cell. In preferred embodiments, the invention includes outputting information from the load cell and adjusting force in the nip in response to the information received from the load cell.

Abstract: A ultrasonic processing method and apparatus (20), can include a rotatable, ultrasonic horn member (28) operatively joined to a first isolation member (42) and a second isolation member (44). In a particular aspect, the first and second isolation members (42, 44) can exhibit high rigidity. A rotatable anvil member (86) can be cooperatively positioned to provide a selected horn-anvil gap (106), and the anvil member (86) can be located in a horizontally offset and vertically overlapping arrangement relative to the horn member (28). An actuator (110) or other transfer device can selectively adjust the horn-anvil gap (106). Additionally, an ultrasonic exciter (82) can connect to the horn member (28), and can provide an operative amount of ultrasonic energy to the horn member (28).

Abstract: An apparatus and method for forming a connection of portions of a moving folded web of disposable undergarments is provided. The apparatus preferably includes a registration conveyor positioned to register and convey a folded web of disposable undergarments moving along a predetermined path of travel and a web connector positioned adjacent the registration conveyor to connect portions of the folded web as the folded web is conveyed along the predetermined path of travel. A method preferably includes registeringly conveying a folded web of disposable undergarments along a predetermined path of travel and connecting portions of the folded web as the folded web is conveyed along the predetermined path of travel.

Abstract: An apparatus and method for joining together two or more fabric components without thread, the components including at least one ultrasonically bondable component. The apparatus comprises an ultrasonic horn operable to emit ultrasonic energy through a fabric-engaging end face thereof, and a rotatable anvil support having an outer peripheral surface on which one or a plurality of anvil supports are formed. The anvil support and the horn are arranged so as to define a nip between the respective fabric-engaging surfaces thereof for receiving the components to be joined. The anvil support rotates about an axis thereof as the components pass through the nip such that the outer peripheral surface of the anvil support defining the anvil structures is stationary relative to the components passing through the nip.

Abstract: Method and apparatus comprising a novel ramped anvil roll for cooperating with a rotary ultrasonic horn and creating ultrasonic bonds in a work piece passing between the anvil roll and ultrasonic horn. A relatively smaller radius portion of the anvil roll extends about a first portion of the circumference, and a relatively larger-radius raised bonding element extends about a second portion of the circumference. An outer surface at at least one of a front and rear end portion of the raised bonding element defines a transition gradient between the raised operating surface and the relatively smaller radius portion. The transition gradient defines a modified sinusoidally-shaped curved loading surface including an inflection locus, the curved loading surface representing a relatively constantly changing angle as measured against respective radii of the anvil roll in combination with advancing along the corresponding portion of the circumference.

Abstract: This invention pertains to apparatus and methods for intermittently creating ultrasonic bonds in sequentially advancing work piece segments, in a nip. The work piece segments are up to about 0.25 inch thick. The apparatus comprises a frame, anvil support apparatus supporting an anvil, and horn support apparatus supporting an ultrasonic horn. The ultrasonic horn and anvil are collectively mounted and configured such that the ultrasonic horn and anvil can be brought together to define the nip. The frame, anvil support apparatus, and horn support apparatus collectively are sufficiently rigid that the horn and anvil can be brought together with interference levels of about 0.000 to about 0.008 inch at a raised bonding portion in combination with defining sufficient nip pressure to develop ultrasonic bonds in work piece segments passing through the nip. The method comprehends bringing a back-up roll, mounted above the ultrasonic horn, into engagement with the ultrasonic horn, to directly support the horn.

Abstract: A bi-directional device for ultrasonically consolidating a fiber reinforced composite structure including a horn which can be angled relative to the composite structure. The horn includes a tip at the distal end of the horn which terminates in a rounded face. The rounded face of the horn contacts the composite structure enabling the horn to be driven bi-directionally over the composite structure at an angle.

Abstract: A device for processing a continuously running strip of material includes an ultrasonic generator unit with a sonotrode that is fixed opposite a counter roller. The material strip is processed in the gap. To adjust the gap height, the force in the gap is measured using a force measuring member, and used for regulation.

Abstract: A method for ultrasound treatment of at least one fabric. The fabric is passed through a working gap between a sonotrode connected with an ultrasound vibration unit and a counter-tool, and is exposed to an ultrasound effect in the working gap. The fabric or fabrics to be treated are subjected to pretreatment in a device before passing through the working gap.

Abstract: A cooling device has a radiator plate and a corrugated fin for cooling an electrical component. In a manufacturing process of the cooling device, a symmetrically constructed tool section presses the radiator plate and the fin against an anvil. The radiator plate has an attaching portion where an electrical component is attached. Knurled surface for preventing a slide is formed on the tool section only at a surrounding area to prevent a deformation of the attaching portion. The tool section and the radiator plate vibrate ultrasonically in a longitudinal direction of corrugations of the fin to prevent a crack on the fin.

Abstract: An ultrasonic sealing apparatus is provided with an excellent sealability. The apparatus is capable of supplying sufficient output energy delivered by an ultrasonic wave-generating device to a thermoplastic resin of a packing material. A tubular packing material is evenly pressed on an appropriate timing in transverse sealing so that the thermoplastic resin is sufficiently softened/melted for an excellent sealing.

Abstract: The invention relates to a device and a method for producing a material laminate (1) by fixing pieces of material (2) at a given distance from one another on a first continuously advanced material web (4). The invention is characterized in that the pieces of material (2) are cut from a second continuous web (7) in a first station (3) and are conveyed via a transport device (10) to the first web (4), to which the piece of material (2) is attached by means of ultrasonic welding over a limited attachment area (5) on the pieces of material (2), and the pieces of material (2) are subsequently fixed to the material web (4) by ultrasonic welding in a second station (6). The second station comprises an ultrasonic horn (18) at a fixed distance from a stay (19) designed as a rotating drum with a patterned outer surface.

Abstract: An apparatus and method for forming a connection of portions of a moving folded web of disposable undergarments is provided. The apparatus preferably includes a registration conveyor positioned to register and convey a folded web of disposable undergarments moving along a predetermined path of travel and a web connector positioned adjacent the registration conveyor to connect portions of the folded web as the folded web is conveyed along the predetermined path of travel. A method preferably includes registeringly conveying a folded web of disposable undergarments along a predetermined path of travel and connecting portions of the folded web as the folded web is conveyed along the predetermined path of travel.

Abstract: Bonding apparatus and methods for creating up to full-width ultrasonic bonds in an advancing web. The bonding apparatus comprises a first nip, defined by, in combination, a first set of bonding elements comprising a first rotary ultrasonic horn and a first rotary anvil, and first engagement apparatus bringing the first horn and first anvil into effective bonding engagement with each other. The first horn and anvil being supported from support structure and rotating in common with each other thereby to convey the web through the first nip. The bonding apparatus also comprises a second nip, defined by a second set of bonding elements comprising second separate and distinct horn and anvil, and second engagement apparatus bringing the second horn and second anvil into effective bonding engagement with each other.

Abstract: A method of manufacturing a filter comprises the steps of assembling multiple layers of filtration material on top of one another to form an assembly; holding the assembly between an ultrasonic weld horn and a weld nest so that the assembly has a marginal area outside of an edge formed on either the nest or the weld horn; and operating the weld horn so as to cause the marginal area to be cut off from the assembly at the edge and to simultaneously seal together the layers of filtration material of the remaining assembly at the edge. A filter made by the process and an apparatus used to practice the process are also disclosed.

Abstract: This invention pertains to apparatus and methods for intermittently creating ultrasonic bonds in sequentially advancing work piece segments, in a nip. The work piece segments are up to about 0.25 inch thick. The apparatus comprises a frame, anvil support apparatus supporting an anvil, and horn support apparatus supporting an ultrasonic horn. The ultrasonic horn and anvil are collectively mounted and configured such that the ultrasonic horn and anvil can be brought together to define the nip. The frame, anvil support apparatus, and horn support apparatus collectively are sufficiently rigid that the horn and anvil can be brought together with interference levels of about 0.000 to about 0.008 inch at a raised bonding portion in combination with defining sufficient nip pressure to develop ultrasonic bonds in work piece segments passing through the nip. The method comprehends bringing a back-up roll, mounted above the ultrasonic horn, into engagement with the ultrasonic horn, to directly support the horn.

Abstract: A machine and process are disclosed for bonding an elastic member to a moving substrate web while the elastic member is in an un-stretched condition. The machine provides for upwardly folding a moving substrate web along a longitudinal centerline while maintaining the side edge regions of the web in a flat un-folded or un-gather condition. An elastic member is applied to the moving web while the elastic member is un-stretched, applying the first and second end regions of the elastic member to the respective first and second side edge regions of the moving web. The end regions of the elastic member are next bonded to the side edges of the web, leaving the remainder of the elastic member un-bonded to the web. The web is then un-folded or un-gathered to its first normal width, stretching the bonded elastic member. At least a portion of the remainder of the elastic member previously un-bonded to the web is then bonded to the web, and the stretched elastic member is allowed to relax.

Abstract: The invention solves in a new manner the known problems of making packages in the form of a continuous tube completely and reliably tight though a method, which is mainly distinguish by the tube being pressed together at the constricting positions into a string and that the string along plural lines are subjected to high and preferably pulsating pressure of such a magnitude that the material becomes adhering. The lines may be traversal with respect to the tube ot crossing each other so as to form a checked pattern. The pulsation in pressure is suitably obtained through ultrasound. The invention concerns a device as well as a sealing method.

Abstract: A rotary bonding apparatus includes a rotatable drum and one or more bonding elements, for example, ultrasonic horn and anvil assemblies, which rotate with the drum. The drum includes a web-supporting surface, and web material which is to be bonded rotates with the drum. The web material is positioned between the bonding elements and the web and bonding elements rotate at the same velocity so that the bonding elements are stationary relative to the web being bonded.

Abstract: An apparatus for friction welding a first element to a second element includes a forge assembly having a table defining a platform, a crank, a forge link and a reaction link disposed oppositely of the forge link relative to the platform. Various construction details are disclosed that provide a friction welder that minimizes bending in the forge and motion planes and enhances repeatability of the welds performed. In a specific embodiment, the friction welder may be used in a method to form integrally bladed rotors and further includes a reciprocal motion assembly adapted to generate motion between the elements being welded, a gripper and an base tool. The reciprocal motion assembly includes a servo hydraulic actuator having a hydraulic column frequency greater than the frequency of reciprocation. The gripper is a device for use with bonding an airfoil to the rotor. The base tool is a device for mounting and positioning the rotor for the bonding operations.

Abstract: A flat cable includes first and second insulator sheets, and a plurality of conductor elements arranged in parallel relation to one another over the length of the sheets. The first insulator sheet is provided with an adhesive layer. The conductor elements are interposed between the adhesive layer and the second insulator sheet. The first and second insulator sheets are first press-adhered under heat through the adhesive layer, and then bonded by an ultrasonic welding unit. The ultrasonic welding unit includes a horn for imparting ultrasonic oscillations, and an anvil placed in opposition to the horn. The first and second insulator sheets are bonded in the zones which extend along the length of the sheets and are located outside the loci where the conductor elements are arranged. The bonding is performed either continuously or in an intermittent manner. In a flat cable thus produced, the conductor elements embedded therein are efficiently prevented from mutual short-circuiting.

Abstract: A device for treating a continuously advancing material web with ultrasound includes an ultrasound generator and a sonotrode, rigidly connected with the former in a manner so as to transmit ultrasound. The sonotrode has a face which lies opposite a counter-tool. The material web is passed through the gap. The module composed of the ultrasound generator and the sonotrode is connected with the machine frame via a piezoelectric actuator, by means of which small displacements of the face of the sonotrode relative to the circumference surface of the counter-roller can be balanced out.

Abstract: The invention provides an apparatus for use with containers 11 each in the form of a rectangular or square tube and having an open upper end and an outlet 25 in a top forming portion 12 of the container, for bonding a pour spout 31 to the container edge portion defining the outlet. The apparatus comprises a conveyor 41 for transporting the containers 11 so as to halt the containers successively at a bonding station, and a support 44 movable into contact with the outlet-defining edge portion of the container 11 as halted at the bonding station from inside the container for receiving the pressure of bonding. The support 44 is so disposed as to be movable into and out of the container 11 along an arc path and has a contact face 83 facing outwardly of the arc path.

Abstract: An ultrasonic tool has an air actuated acoustic horn assembly. An electronic and pneumatic controller generates a predetermined air pressure within the tool. The horn assembly is coupled to the controller for applying a desired actuation force to a part based on the predetermined air pressure. The predetermined air pressure therefore corresponds to the desired actuation force. The horn assembly also transmits mechanical vibrations to the part at a predetermined frequency. The tool further includes an acoustic control system coupled to the horn assembly for transferring a high frequency electrical voltage to the horn assembly. Selectively applying the desired actuation force to the part based on air pressure allows a wider range of forces to be applied, and eliminates problems associated with part damage and marking.

Abstract: An apparatus and method for effecting an operation on at least one moving substrate web is disclosed. The apparatus comprises a rotatable bonding roll that is located adjacent the substrate web and configured to rotate about a bonding axis. A rotatable anvil roll has an anvil surface and is configured to rotate about an anvil axis to press the substrate web against an outer peripheral bonding surface of the bonding roll thereby bonding the substrate web. At least three support wheels are configured to contact the bonding surface of the bonding roll and to hold the bonding roll in a substantially fixed position.

Abstract: A high-frequency heat-sealing apparatus is provided which is capable of achieving a satisfactory seal in which a sealed zone is narrower in its width than at its central portion and in which contaminants such as liquid beverages are not present between thermoplastic material layers over the longitudinal direction of the sealed zone. The apparatus transversely heat-seals a tubular packing material made of a laminate including a synthetic resin layer and a conductive material layer in the presence of a fluid. A ridge shaped to contain an arcuate partial curve in its transverse contour is formed on the action face of a high-frequency coil flush with the flat action face of one of the pressing members for pressing the central portion of a sealed zone having two rounded and narrowed right and left sides. A flash portion for a molten thermoplastic resin is formed adjacent to the outer side of the high-frequency on the cutting side of the coil.

Abstract: The invention includes of a system and method of ultrasonically perforating adhesive bandage backings. The invention eliminates the gap between the ultrasonic horn and the pin roll, and provides for a wear resistant release coating on the pin roll. Further, the method and system disclose cooling the ultrasonic horn with a forced air stream, and provide for a pre- or post-nip roll to control the tension of the continuous web of backing. The web of backing is kept under tension with a nip roll, and passes between an ultrasonic horn and an immediately adjacent pin roll for perforation by the ultrasonic horn. The resulting material of the web backing is smoother, and has better hole quality than that seen in the prior art.

Abstract: A bi-directional device for ultrasonically consolidating a fiber reinforced composite structure including a horn which can be angled relative to the composite structure. The horn includes a tip at the distal end of the horn which terminates in a rounded face. The rounded face of the horn contacts the composite structure enabling the horn to be driven bi-directionally over the composite structure at an angle.

Abstract: An improved method and apparatus is provided for continuously embossing a precision pattern of micro-prismatic elements on a surface of a resinous sheeting material with the aid of an endless metal embossing belt. The method includes the steps of moving the belt along a closed path through a heating station and a cooling station, conveying superimposed resinous film and sheeting material into proximity with the belt, passing the film and sheeting between the belt and a series of sonic welding heads to thereby begin to impress a pattern of micro-prismatic formations of the belt into one surface of the sheeting, pressing the film and sheeting against the heated belt until the one surface of the sheeting fully conforms to the embossing pattern, and stripping the film and embossed sheeting from the belt.

Abstract: A manufacturing apparatus and method for assembling a food container having a body portion with an annular rim configured to be secured to an annular rim of a base portion of the container. The manufacturing apparatus and method includes a container supporting assembly, a tool member, a drive assembly, an oscillator assembly and a suspension assembly. The container supporting assembly supports the body and base portions of the container with the annular rim of the base portion engaging the annular rim of the body portion. The drive assembly moves the tool member along a first axis between a first position, wherein the tool member is engaged with the annular rim of the base portion, and a second position, wherein the tool member is disengaged therefrom. The oscillator assembly oscillates the tool member relative to the container supporting assembly to cause oscillation of the base and body portions relative to one another.

Abstract: A processed fiber is used to distribute energy from an electromagnetic (EM) energy source to a material in which the fiber is embedded. The electromagnetic energy source supplies electromagnetic energy to the fiber and the fibers emit portions of the EM energy along the length of the fiber. The sealant material absorbs a quantity of the electromagnetic energy sufficient to cure the sealant material and propagates excess electromagnetic energy through the sealant material without significant additional absorption. This prevents the sealant material from over-curing. Additionally, a fully cured material can be used to generate thermal energy and thereby serve as a heat blanket that can be used to de-ice aircraft.

Abstract: To provide an ultrasonic welding apparatus of a simple structure which allows a plastic fastener to be automatically loaded into an ultrasonic horn, and to provide an ultrasonic welding method of high operational efficiency. An ultrasonic welding apparatus 1 includes an ultrasonic horn 3 holding a plastic stud 7 having a flange 5 and an engagement shank 6, and a body 2 to bring the flange of the stud 7 held by the ultrasonic horn into contact with a workpiece, so that the flange 5 is ultrasonic-welded onto the workpiece. The ultrasonic welding apparatus further includes a stud receiving member 10 to receive the plastic stud 7 in the manner that the flange is advanced ahead from a feeding tube 9; and a moving mechanism (a first arm 19, a first arm cylinder 21, a second arm 23, a second arm cylinder 25, and the like) to move the stud receiving member 10 to a position below the ultrasonic horn 3.

Abstract: An ultrasound welding component is disclosed. One embodiment of the component includes a weld region about which an ultrasound weldable material may be wrapped. The weld region includes a weld zone consisting of recesses positioned on opposing sides of a weld area. The recesses and weld area each having widths selected such that an ultrasound source compressing overlapping sections of the ultrasound weldable material against the weld area forms a weld having a width which is narrower than a sum of the widths of the recesses and the weld area. The component also includes a mechanism which immobilizes the ultrasound weldable material relative to the weld zone.

Abstract: An improved method and apparatus is provided for continuously embossing a precision pattern of micro-prismatic elements on a surface of a resinous sheeting material with the aid of an endless metal embossing belt. The method includes the steps of moving the belt along a closed path through a heating station and a cooling station, conveying superimposed resinous film and sheeting material into proximity with the belt, passing the film and sheeting between the belt and a series of sonic welding heads to thereby begin to impress a pattern of micro-prismatic formations of the belt into one surface of the sheeting, pressing the film and sheeting against the heated belt until the one surface of the sheeting fully conforms to the embossing pattern, and stripping the film and embossed sheeting from the belt.

Abstract: In an apparatus for machining a material web by means of a sonotrode, the pressure force of the sonotrode is determined and is used as a control signal for the advance of the sonotrode, as a result of which the nip height is set.